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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32702
Location: Reading Pennsylvania
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dabaron
Samba Member
Joined: June 21, 2018
Posts: 2593
Location: Philly, mang
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 Posted: Thu Dec 16, 2021 6:07 am Post subject: Re: The mania deepens: 1991 Full Westy rescue |
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| djkeev wrote: |
That is absolutely ASTOUNDING how fast that hose arrived from England!
They must have had a plane idling on the runway! (Tarmac for you Brits)
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well i do know a VP at UPS... but it was just regular 3 day UPS service. i expected Friday.
the plus, the power steering is working, now to solve the fuel pump bizarre sound.
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1991 Vanagon GL Camper
i had no idea i wanted to be a mechanic |
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Schnippzle
Samba Member
Joined: February 04, 2021
Posts: 288
Location: Swede in London, UK
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| Posted: Thu Dec 16, 2021 6:14 am Post subject: Re: The mania deepens: 1991 Full Westy rescue |
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| djkeev wrote: |
That is absolutely ASTOUNDING how fast that hose arrived from England!
They must have had a plane idling on the runway! (Tarmac for you Brits)
Dave |
Brickwerks do generally provide excellent service. They CS also really, really know their stuff.
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1988 Caravelle - FB25B - Syncro converted
2016 MB E63 AMG S - The daily driver
2019 Harley Davidson FXFBS Fat Bob - The leisure |
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dabaron
Samba Member
Joined: June 21, 2018
Posts: 2593
Location: Philly, mang
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| Posted: Tue Jan 11, 2022 4:34 pm Post subject: Re: The mania deepens: 1991 Full Westy rescue |
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this past weekend i took the Westy camping in New Jersey at Freeze Your Bus Off. the Westy ran well and it was a nice first trip after sorting out the burnt valve.
here are some observations/thoughts from the trip:
the coolant temp gauge was reading lower than normal. might be due to the sub-freezing temps, something to keep an eye on.
the power steering hose from Brickwerks is great, no power steering hose noise like on the Go Westy product.
all the noise i hear is the fuel pump... it made the weird "cavitation" noise infrequently, mostly its a loud spinning motor type noise i hear from the fuel pump. it's loud.
the Mr. Buddy is not a long term heating solution. it's great for taking the chill off in the shoulder season, not for temps hovering just under 20F.
cooking with the top down is no fun.
my boots were frozen to the floor in the morning. it was cold.
the LiFePo4 battery system worked flawlessly. i never turned on the fridge, it was a great place to keep my beverages from freezing 
i missed camping in the Westy, it feels like there was a time vortex that made Nov and Dec feel like 2 years. such a strange feeling.
i traveled 150 miles round trip and the engine required no fluids. on my last trip the engine consumed nearly 1/2 a quart of oil every 150 miles!
the Peloquin is interesting on ice. once it engages.
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1991 Vanagon GL Camper
i had no idea i wanted to be a mechanic |
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32702
Location: Reading Pennsylvania
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dabaron
Samba Member
Joined: June 21, 2018
Posts: 2593
Location: Philly, mang
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| Posted: Tue May 17, 2022 9:39 am Post subject: Re: The mania deepens: 1991 Full Westy rescue |
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i have put about 1000 miles on the Westy since replacing the burnt valve. i'm pulling the engine to replace the flex plate and main seal this week and wanted to check how the valve was doing....
warm engine, solid number. happy am i.
plug looks decent as well.
feeling confident the issue has been resolved and our trip thru New England at the end of June will be filled with miles of smiles.
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1991 Vanagon GL Camper
i had no idea i wanted to be a mechanic |
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32702
Location: Reading Pennsylvania
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dabaron
Samba Member
Joined: June 21, 2018
Posts: 2593
Location: Philly, mang
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| Posted: Wed May 18, 2022 10:33 am Post subject: Re: The mania deepens: 1991 Full Westy rescue |
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the spring broke in the slider door latch mechanism. the slider will not stay unlocked, the spring kept the internal lock lever in the proper position.
i pulled it apart and decided it was a much larger job than simply replacing a spring... rivets would need to be drilled and then replaced to keep the latch assembly together. it was going to be a several hour job.
this thread had some good info on a low cost, low effort workaround. i like low cost, low effort solutions...
https://www.thesamba.com/vw/forum/viewtopic.php?t=767283
a 3/8" grommet is perfect, adds plenty of friction and won't move around. thanks thesamba!
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1991 Vanagon GL Camper
i had no idea i wanted to be a mechanic |
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dobryan
Samba Member
Joined: March 24, 2006
Posts: 16521
Location: Brookeville, MD
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32702
Location: Reading Pennsylvania
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dabaron
Samba Member
Joined: June 21, 2018
Posts: 2593
Location: Philly, mang
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| Posted: Wed May 18, 2022 4:30 pm Post subject: Re: The mania deepens: 1991 Full Westy rescue |
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i found putting the ever so smallest amount of lithium grease in the inside slot of the grommet allows it to slide freely but still have plenty of friction to stay in place. the grommet is pushed outward by the lock dowel.
we'll see how it holds up. there is a spare in the drawer.
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1991 Vanagon GL Camper
i had no idea i wanted to be a mechanic |
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dabaron
Samba Member
Joined: June 21, 2018
Posts: 2593
Location: Philly, mang
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| Posted: Thu May 19, 2022 6:01 pm Post subject: Re: The mania deepens: 1991 Full Westy rescue |
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time to address the oil leaking from the main seal. my suspicions were it was the flex plate that would need replaced, there was a slight groove worn in it when I rebuilt the engine (the first time) so I assumed the groove had only gotten deeper. Monday I ordered the last flex plate from Brickwerks and…
came home today to a package from Brickwerks!
pulled the engine, that hoist was a smart buy.
as I suspected, groove worn deeper.
the new part is OG VW… I tried to salvage the sticker, but it tore apart.
more to come…
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1991 Vanagon GL Camper
i had no idea i wanted to be a mechanic |
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dabaron
Samba Member
Joined: June 21, 2018
Posts: 2593
Location: Philly, mang
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| Posted: Mon May 23, 2022 4:35 pm Post subject: Re: The mania deepens: 1991 Full Westy rescue |
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with the new OG VW flex plate cleaned up and the end play shim dance complete, it's time to install the sucker. luckily i had a new o-ring on hand...
first task is getting the new SABO seal installed. i splashed out for the Go Westy tool. with a smear of Rezosil added, it's ready to go.
this tool is really nice. the seal went in super easy.
seal installed and the black goop cleaned up.
flex plate installed with new bolts and torqued to 81 ft pounds.
end play is at 0.0045" - i'll take it.
i get a bunch of use out of the tap and die set i purchased a few years ago. i chased all the bolts and nuts, including the threads on the torque converter
hurray and up she rises
bolted in and ready to finish the install.
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1991 Vanagon GL Camper
i had no idea i wanted to be a mechanic |
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dabaron
Samba Member
Joined: June 21, 2018
Posts: 2593
Location: Philly, mang
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| Posted: Tue May 24, 2022 1:45 pm Post subject: Re: The mania deepens: 1991 Full Westy rescue |
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finished connecting all the things, added the coolant and took it out for a "tony tune up" - once the lifters quieted down i could hear the fuel pump buzzing away. i really want to get that resolved.
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1991 Vanagon GL Camper
i had no idea i wanted to be a mechanic |
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dabaron
Samba Member
Joined: June 21, 2018
Posts: 2593
Location: Philly, mang
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| Posted: Tue May 24, 2022 4:29 pm Post subject: Re: The mania deepens: 1991 Full Westy rescue |
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the fuel pump is still buzzing. the fuel pressure when running is 30 psi with the vac connected, 36 psi disconnected... no issue there... except the residual pressure. the pressure drops immediately after turning off the engine.
with the two returns clamped after ruling out the fuel pump check valve and leaking injectors, the only other culprit could be the fuel pressure regulator.
with both lines clamped the pressure stays high. release one or the other and it drops. with a clamp on the return fuel line, the pressure stays, clamp removed, it drops.
will a new FPR solve the issue? probably not. this was a new FPR 
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1991 Vanagon GL Camper
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djkeev
Samba Moderator
Joined: September 30, 2007
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Location: Reading Pennsylvania
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dabaron
Samba Member
Joined: June 21, 2018
Posts: 2593
Location: Philly, mang
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| Posted: Fri May 27, 2022 7:59 pm Post subject: Re: The mania deepens: 1991 Full Westy rescue |
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took the Westy out for a 35 minute drive doing a mix of city, rural and highway speeds. came home and no leaks, now i can watch the oil level for consumption issues.
glad i got this issue sorted as it has the potential to mask other issues and was making a proper mess of the engine compartment from oil slung about.
i can't stress enough how important a clean engine and transmission are for seeing and tracing problems before they become a crisis for the wallet. do try to keep your jawn clean, mang.
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1991 Vanagon GL Camper
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djkeev
Samba Moderator
Joined: September 30, 2007
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dabaron
Samba Member
Joined: June 21, 2018
Posts: 2593
Location: Philly, mang
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| Posted: Tue Jun 21, 2022 6:12 am Post subject: Re: The mania deepens: 1991 Full Westy rescue |
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been meaning to tackle this simple project, finally got to it...
the kitchen meter panel needs some love
cleaning up the panel with some 220
after a few coats of paint it looks pretty decent
looks pretty good with decals applied.
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1991 Vanagon GL Camper
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djkeev
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